Control system



Feb. 6, 1940. J GRAHAM 2,189,603

CONTROL SYSTEM Filed Oct. :5, 1955 WITNESSES: INVENTOR cf? H /o/dffiraham.

Patented Feb. 6, 1940' UNITED STATES PATENT OFFICE,

CONTROL SYSTEM Pennsylvania Application October 3, 1935, Serial No. 43,358

4 Claims.

My invention relates generally to control systems and it has particular relation to systems for remotely controlling the output capacity of a direct-current generator.

An object of my invention, generally stated, is to provide a system for remotely controlling the output capacity of a direct-current generator which shall be simple and emcient in operation and which may be readily and economically manufactured and installed,

The principal object of my invention is to provide for changing,from a remote position, the output capacity of an electric generator.

vide for utilizing the flow of current in the load circuit of a generator for effecting changes in the output of the generator. 7

Another important object of my invention is to provide for utilizing the flow of a low value of effecting changes in its output capacity and for utilizing the normal flow of current for preventing the operation of the mechanism effecting the 25 changes.

Another object of my invention is to provide for utilizing different values of current flow in the load circuit of a generator for selectively operating a control mechanism to either increase or decrease the output capacity of the generator.

Still another object of myinvention is to provide for utilizing ditferent values of current flow in the load circuit of a generator for selectively operating a control mechanism to either increase or decrease the output capacity of the generator and for utilizing the normal flow of current in the load circuit for preventing the operation of the control mechanism.

Other objects of my invention will in part be obvious and in part appear hereinafter.

My invention, accordingly, is disclosed in the embodiment hereof shown in the accompanying drawing and comprises the features of the construction, combination of elements and arrangement of parts which will be exemplified in the constructions hereinafter set forth and the scope of the application of which will be indicated in the appended claims.

For a more complete understanding of the nature and scope of my invention, reference may be had to the following detailed description taken in connection with the accompanying drawing, in which f Figure 1 illustrates diagrammatically a concrete embodiment of my invention, and

An important object of my invention is to procurrent in the load circuit of a generator for Fig. 2 illustrates diagrammatically a modification of my invention.

In order to remotely control the output capacity of a direct-current generator, such as a welding generator, I have provided a mechanism which is responsive to diflerent values or current flowing in the load circuit of the generator to effect changes in the output capacity of the generator. For example, the generator may be provided with a main field winding which is connected to a source of excitationthrough a fleld, rheostat. A mechanism is provided for operating the field rheostat in either direction in order to either increase or decrease the current flowing through the main field winding. In order to selectively control this mechanism, a current responsive relay system is provided. This current responsive relay system is connected to the load circuit. For example, it may be connected across the differential series field winding of the generator to be responsive to the flow of current in the load circuit,

At the point where the load circuit is connected to the load, for example to the welding arc, one or more resistors may be provided which may be selectively connected to permit diflferent predetermined values of current to flow through the load circuit. Depending upon which of the resistors is connected across the load circuit, an operation will be effected at the generator to either increase or decrease its output capacity.

Referring now specifically to Fig. 1 of the drawing, the reference character ll designates generally a direct-current generator having a dinerential series field winding H which may be con nected, as illustrated, to energize a load circuit represented by .the' conductors l2 and IS. The conductors l2 and It may terminate, respectively, in a welding electrode IQ and work II, on which a welding operation may be performed by means of an arc maintained between the welding electrode l4 and the work ii in the customary and well known manner. The electrode l4 may be carried by a suitable electrode holder ii.

The generator l0 may be provided with a main field winding I! which is connected for energization to an exciter-generator, shown generally at l8, of the series type. In order to drive the generator i0 and the exciter generator ll, an alternating currentmotor l 9 may be provided, as illustrated, and connected to a suitable source of alternating current by means of conductors A, B, C.

The current fiow through the main field winding l1 may be controlled by means of a field rheostat, shown generally at 20, having a resistor 2| connected in series circuit relation between the exciter-generator i 8 and the main field winding l7. A movable arm 22 is provided for varying the eflective resistance of the resistor 2| connected in the circuit. As shown, the arm 22 is mounted on a shaft 23 on which are also mounted ratchet wheels 24 and 26.

The ratchet wheel 24 may be operated by means of an electro-magnet shown generally at 28, having an armature 26w connected to operate a pawl 21 which, as shown, is arranged to engage the ratchet wheel 24. The electromagnet 26 is also provided with an operating winding 26w,

which may be connected for energization across the terminals of the exciter-generator I8 in a manner which will be set forth hereinafter. In like manner, the ratchet wheel 25 may be operated in an opposite direction by means of an electromagnet, shown generally at 28, having an armature 28a connected to a pawl 29 and an operating winding 28w which may also be energized from the exciter-generator l8.

Theelectromagnets 26 and 28 may be selectively controlled by means of a main control relay shown generally at 3|. This relay is provided with contact members 3M: and My which are connected respectively to the operating windings 2810 and 2520. An armature 3la is arranged to will be induced therein by the leakage flux from the magnetic circuit of relay II on energization of windings ilwv and llwc.

The main control relay ii is, in turn, controlled by means of an auxiliary control relay, shown generally at 32.' This relay is provided with contact members 322: and an operating winding 32w.

In order to prevent the functioning of the control system while the load circuit is carrying normal current, a cut-oi! relay, shown generally ata, is provided having contact members 33:: which are normally closed. and an operating winding "to. On the fiow of normal current in the load circuit, the operating winding 3311) is sufliciently energized to open contact members "2:; otherwise they remain in the closed condition in order to permit the effecting of the difi'erent control functions.

The control mechanism .is selectively operated by means of resistors L and R which may be. mounted in any suitable container and carriedby the welding operator. The resistor L may be arranged to permit the' flow of 10 amperes of current in the load circuit and when such current fiows, the rheostat 2|! is operated in such a direction as to decrease the flow of exciting current in the main field winding l1, and, therefore,

to lower the output capacity of the generator I 0. In like manner, the resistor R may be 01' such value as to permit the flow of current in the load clrcuit, as for example 25 amperes, which will be sumcient to operate the rheostat 20 in a reverse direction to increase the .fiow of exciting current in themain field winding l1 and, therefore, to increase the output capacity or the generator ll. 7 a

In describing the operation of the system, it

. will be assumed that the motor I! is energized and is operating the generator l0 and the excitergenerator 18 at the proper speed. It will further be assumed that the welding electrode I4 is out of engagement with either 01' the resistors L or R and also out of engagement with the work it. Under these conditions, the various relays and operating mechanisms will be in the positions illustrated in the drawing.

Assuming that the operator wishes to lower the output capacity of the generator l0, he will cause the welding electrode II to engage one terminal of the resistor-L, the other terminal of which is connected, as illustrated, to the load conductor I 3. Current will then be caused to flow through the load circuit at a value corresponding to the resistance of the resistor L which may be taken, as set forth, to be 10 amperes. It will be observed that the operating windings 8 two, 3210 and 33w are connected in series circuit relation and across the diflerential series field winding ll. Thus the flow of'10 amperes in the load circuit will cause a flow of current through these operating windings proportionate to this value of current flowing through the difierentlal series field winding I I. While the system has been illustrated as being connected across the differential series field winding, it will be obvious that any minimum value of control current, and, therc- Y fore, an energizing circuit is completed, not only for the operating winding llwv oi the main control relay 3| but also for one or the other of the operating windings 2610 or 2810 depending upon the position of the armature 3la.

Since the minimum value of control current is caused to fiow through the load circuit on fiow of current through resistor L, the flux generated by the operating winding 3lwc will be less than the flux generated by the operating winding 3 two. As a result, the armature 3 la will be attracted to engage contact members 3M: and the operating winding 28w will be energized to operate the field rheostat 20 in such a direction as to increase the resistance in series circuit relationof the exciter-generator II. It will be observed that the operating winding ilwv is connected in parallel circuit relation with the operating winding Ilw.

As soon as the operator moves the welding electrode M from the upper terminal or the resistor L, the operating winding 3210 will be deenergized and contact members 322: will be opened. The previously described control circuit will, therefore, be'opened and the operating windings Ilw and llwv will be deenergized. By repeatedly areaeos opening and closing the circuit through the resistor L, it is possible to successively effect the operation of the field rheostat 23 in steps to increase the resistance connected in series' circuit relation with the main field winding ll.

When it is desired to raise the output capacity of the generator ill by decreasing the resistance connected in series circuit relation with the main field winding H, the operator may cause the welding electrode H to engage the upper termiml of the resistor R, the other terminal of which is connected to the conductor I3. The current now caused to flow through'the' load circuit is considerably increased over that which previously fiowed when the resistor L was connected and may be, for example, 25 amperes, as mentioned hereinbefore.

Since the cut-off relay 33 is arranged to operate its contact members only on the fiow of a larger value of current, for example 50 amperes, its contact members will still remain closed on fiow of the larger control current. The flow of the larger control current causes a greater flow of current in the operating winding Shoe and this is so adjusted as to generate a fiux which is greater than the fiux generated by the operating winding 3lwv. As a result, the armature 3ia is attracted to engage the contact members 3h: and, therefore, the operating winding 26w of the electromagnet 28 is energized.

The circuit for energizing the operating winding 2610 may be traced from-one terminal of the excites-generator I! through conductor 35, con.- tact members 3311, conductor 38, contact members 323:, conductor 31, armature 3la, contact member 3H1, conductor H, operating winding 2610, conductors l2 and 40 to the other terminal of the exciter-generator II.

By repeatedly making and breaking the load circuit through the resistor R, it is possible to successively operate the electro-magnet 26 to move the armature 22 in such a direction as to decrease the effective resistance connected in series circuit relation with the main field winding I'I.

After the rheostat 20 has been properly adiusted by the operator to provide the setting required tosupply the desired amount of load current, he may begin the welding operation. This will be accomplished in the usual manner by causing the electrode H to engage the workll to draw the welding arc. Under normal operating conditions, the fiow of current in the load circuit will be relatively high as compared to the flow of current in the resistors L or R. This fiow of current is enough to sufilciently energize the operatingwinding 33w of the cut-oil relay 33, so that contact members 33:: are opened. The energizing circuits for the electro-magnets 23 and 33- are thereby opened and no operation thereof can take place while normal current is flowing in the load circuit. As soon as load current ceases to flow, contact members 33:: are "closed and the control circuit isconditioned for completion at contact members 32:: and 3|.: or 3W, depending upon whether the resistor L or the resistor R. is engaged by the electrode I 4.

Referring now particularly to Fig. 2 of the drawing, it will be observed that certain modifications of the circuit connections illustrated in Fig. 1 are there shown. In this modification of the invention, a generator III is. provided having a series field winding I I as set forth hereinbefore. However, this generator may be of the type shown in Pate No. 1,979,665 issued November 6, 1934,

to J. H. Blankenbuehler, and assigned to the assignee of this application. The generator I! is arranged to supply current to a load circuit comprising the conductors l2 and I3, which terminate, respectively, in an electrode ll and work I! on which the welding operation is to be performed. As described hereinbefore, the electrode Il may be held by means of an electrode holder It.

The output capacity of the generator I! may be varied, as set forth in the aforementioned patent, by employing a magnetic shunt 50. The position of the magnetic shunt Ill may be controlled by means of a reversible control motor, shown generally at The motor BI is provided with an armature 52. In order to operate the motor ii in opposite directions, separate field windings 33 and 54 are provided, which may be oppositely energized. It will be understood, however, that any other suitable type of reversible motor may be employed and that the motor 5 I, shown herein, is used merely for illustrative purposes.

The armature 32 of the motor Il may be energized by direct current which is obtained through a transformer, shown generally at 55, having a primary winding 53 connected between conductors A and B of the three-phase supply line which is connected to energize the motor [9 which may be provided for driving the generator Ill. The transformer 55 is also provided with a-secondary winding 51 that is connected to a rectifier, shown generally at 58, which is preferably of the dry or copper-oxide type. The armature 52 is connected, as illustrated, across the direct-current terminals of the rectifier 53. It will be under- Y stood that the motor 5| is provided in lieu of the electro-magnetic means which is provided in Fig. 1 for effecting the operation of the rheostat 20. It will also be understood that the motor 5| may be employed instead of the electro-magnetic means for operating this rheostat.

As will be readily apparent, the functions of the cut-off relay 33 and the auxiliary control relay 32 may be combined in the operation of the main control relay 3| Thiscombination is shown in the control relay illustrated generally at 80 in Fig. 2. In order to more clearly describe the functioning of the main control relay 80, as including the functions of the cut-off relay 33 and the auxiliary controlrelay 32, the same ref- In addition, the same reference characters have i been applied to the operating windings of the main control relay 33 as are applied to the operating windings of the main control relay 3|. In order to more clearly set forth the circuit connections, the armature lid and the armatures for contact members 32.1: and 33s: have been shown as being in the plane including the magnetic circuit for the relay 60. It will be understood, however, that they may be positioned in a plane at right angles to their present location in order to secure more suitable operating conditions.

In the operation of the main control relay 60 the armature 3la is caused to engage either contact member 3i: or 3| 1!, depending upon whether the fiux generated by the operating winding 3Iwv is greater or less than the fiux generated by the operating winding 3lwc. Contact members 321 are so arranged that they will be closed regardless of whether or not the flux generated by the operating winding 3|wv is greater than the flux generated by the operating winding 3|wc. It will be readily understood that this operation may be efiected since the operating winding 3| we is first energized and it is necessary to close contact members 32:1: before operating winding Slum is energized. Contact members 32$,'thereiore, are magnetically sealed closed and with a proper design of the magnetic circuit of the main control relay 60, they will not be reopened, even though the flux generated by the operating winding 3|wv is greater than the flux generated by the operating winding 3|wc under certain operating conditions. Contact members 33:: are so adjusted as to be opened only when normal current flows through the load circuit of the generator l0.

In order to selectively control the functioning of the main control relay a resistor BI is provided, which takes'the place of the two resistors L and R, shown in Fig. 1 of the drawing. The resistor 5| may be incorporated in the handle of the electrode holder It, so that a compact device requiring a minimum of parts may be carried by the operator. The resistor BI is provided with taps 62 and 53, which may take the form of buttons or the like, protruding through the handle of the electrode holder |5. In order to effect the functioning of the main control relay the operator may contact either tap 62 or 63 with the work l5, depending upon the direction in which he wishes to operate the motor |5.

In operation, assuming that the operator wishes to energize the control motor 5| in a di-.

rection corresponding to the energization of the field winding 54, he'will cause tap 62 to engage the work |5. The greater value of control current will then flow through the load circuit and through the series field winding I l. The operating winding 3|wc will, therefore, be energized and contact members 32:1: will be closed. A circuit will then be completed for energizing operating winding 3|wv.

The circuit for energizing the operating wind-' ing 3|wv may be traced from the positive terminal of the rectifier 58 through conductor 65, operating'winding 3|wv, conductor 66, contact members 32m, contact members 3.31: and conductor 61 to the negative terminal of the re'ctiher 58.

Since the flux generated by the operating winding 3|wc under these conditions is greater than the flux generated by the operating winding 3| wv, the armature 3|a is caused to engage contact member 3|y and field winding 54 is energized.

The circuit for energizing the field winding 54 may be traced from the positive terminal of the rectifier 58, through conductors 85 and 68, field crates.

winding 54, conductor 59, contact member fly, armature 3|a, conductor 66, contact members 321:, contact members 33:: and conductor Ii'l to the negative terminal of the rectifier 58.

As long as the operator causes the tap 52 to remain in contact engagement with the work l5, the contact member 3|y will be engaged by the armature 3|a and the motor 5| will be continuengage the work operating winding 3|wc. As a result, the field winding 53 is energized in a manner similar to the energization of the field winding 54. and the motor 5| operates in a reverse direction. The motor 5| will continue to operate in this directionas long as the operator holds the tap 53 in engagement with the work |5. As soon, however, as it is moved out of engagement with the work I5, the armature 3|a. is released and the field winding 53 is deenergized. The motor 5| then ceases to operate to move the magnetic shunt 50.

As soon as the desired setting of the magnetic shunt 50 is obtained, the operator may begin the welding operation by causing the electrode H to |5. A current then flows through the load circuit which is considerably greater. than the current which fiows therethrough when either of the taps 62 or 63 of the resistor 5| is caused to engage the work |5. This current is sufficient to cause the contact members 331: to be opened and, therefore, during normal operation of the system, neither of the field windings 53 or 54 can be energized.

Since certain further changes may be made in the foregoing constructions and different embodiments of the invention may be made without departing from the scope thereof, it is intended that all matter set forth in theforegoing description or shown in the accompanying drawing shall be considered as illustrative and not in a limiting sense.

I claim as my invention:

1. A remote control system for an electric generator connected tosu'pply current to a load circuit comprising, a source of substantially constant voltage, electro-responsive means for varying the output of the generator, a pair of resistors disposed to be selectively connected across I the load circuit to produce the' flow of control currents of different values therein, and means including a differential control relay having opposed operating'coils one of which is connected to be energized in accordance with the voltage of a the source and the pther connected to be enersized in accordance with the said control currents for selectively controlling the energization and operation of the output varying means of the generator in response to the flow of said control currents therein.

2. A remote control system comprising, in combination, an electric generator, means for varying the output of the generator, a source of substantially constant voltage, electro-responsive means for actuating said output varying means, energizing circuits for said electro-responsive means, a differential control relayhaving opposed operating coils one of which is connected to be responsive to the voltage of said source and the other to be responsive to the flow 01 control currents of different predetermined values in the load circuit of the generator for partially completing the said energizing circuits for the electro-responsive means, resistor means disposed to tially completed by the differential control relay.

3. A remote control system for an electric generator connected to supply current to a load circuit comprising, in combination, electro-responsive means for effecting either an increase or a decrease in the output of the generator, a source of substantially constant voltage. a pair or resistors disposed to be selectively connected across the load circuit to produce the flow therein or two diflerent values of control current of less magnitude than the normal load current flowing therein, energizing circuits connecting said electro-responsive meanswith the saidvoltage source, adiiierential relay having first and second opposed operating windings for selectively controlling the energlzation oi said energizing circuits, said first operating windings being connected for energization in accordance with the flow or said control currents in the load circuit and .said second operating windings being responsive to the voltage of said source, and an auxiliary control relay having normally open contact members connected in circuit relation with the said second operating winding and the energizing circuits for the electro-responsive means and responsive to the flow of either of said control currents in the load circuit for rendering the diiierential relay eflective to control the operation of the electro-responsive means.

4. A remote control system for an electric generator connected to supply current to a load circuit comprising, electro-responsive means for varying the output of the generator, a source of substantially constant excitation voltage for the generator, a pair of resistors disposed to be selectively connected across the load circuit to produce the flow therethrough of different values of control current less than the normal load current of the generator, a differential control relay having opposed operating coils one of which is connected to be responsive tothe voltage of said source and the other of which is connected to be responsive to said control currents for controlling the operation of the electro-responsive output varying means, an auxiliary control relay operable in response to the flow of said control currents in the load circuit to render the diflerential control relay eflective to perform controloperations, and a cut-ofi relay operable in response to flow of a current in the load circuit greater than the control currents for rendering the diflferential control relay ineffective to control the output varying means of the generator thereby to preclude variation in the output thereof under normal load conditions.

I HAROLD J. GRAHAM. 

